Order picker truck with a zoned operator platform covering

ABSTRACT

A vehicle including a chassis and an operator platform for use by an operator. The operator platform is fixed to said chassis, and vertically movable relative to said chassis for lifting the operator. A covering is fixed to the operator platform, such as to a horizontal surface of the platform, where the operator stands. The covering has a driving zone where the operator stands while driving the vehicle and a picking zone where the operator steps when the operator picks an item from a location adjacent the operator platform.

CROSS REFERENCES TO RELATED APPLICATIONS

[0001] Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

[0002] Not Applicable

BACKGROUND OF THE INVENTION

[0003] The present invention relates to order picker trucks having operator platforms, and more particularly to order picker trucks having coverings on the operator platform which have more than one zone for supporting an operator.

[0004] Order picker trucks are used to pick products from shelves in order to fill a customer order. The products are typically stored in a rack system in which a plurality of unit loads of many products are stored. Each unit load, generally, contains a single type of product, and a customer typically requires one or more boxes of product picked from many different unit loads. This requires an operator to travel up and down one or more aisles of the rack system to pick products from many different locations in the rack system to fill the customer's order.

[0005] An order picker truck is typically driven down an aisle by the operator standing on a vehicle operator platform which forms part of the vehicle. The operator drives the vehicle with the left foot on a brake pedal, the left hand on a vehicle steering wheel, and the right hand on a multi-functional control handle. When the operator reaches a desired location in the aisle, the vehicle is stopped, the operator steps toward an edge of the operator platform to pick a box from a rack location and places the box on a pallet adjacent the operator platform.

[0006] When the operator drives the vehicle, vibrations transmitted through the vehicle to the operator platform cause discomfort to the operator. In order to reduce these vibrations a cushioning mat can be placed on the vehicle operator platform which isolates the operator from the vibrations. Unfortunately, the softness of the cushioning mat can provide an unstable footing for the operator when the operator reaches into the racks or places a picked box on the pallet. Accordingly, a need exists for an order picker truck including an operator platform having a covering which both reduces vibrations transmitted to the operator while the vehicle is moving and provides stable footing for the operator when the operator is picking a item from the rack or placing the item on a pallet adjacent the operator platform.

SUMMARY OF THE INVENTION

[0007] The present invention provides a vehicle including a chassis and an operator platform for use by an operator. The operator platform is fixed to said chassis, and vertically movable relative to said chassis for lifting the operator. A covering is fixed to the operator platform, such as to a horizontal surface of the platform, where the operator stands. The covering has a driving zone where the operator stands while driving the vehicle and a picking zone where the operator steps when the operator picks an item from a location adjacent the operator platform.

[0008] A general objective of the present invention is to minimize vibrations transmitted to the operator when the operator is operating the vehicle, and to provide stable footing for the operating when the operator is picking an item from a location adjacent the operator platform or placing an item on the load platform. This objective is accomplished by providing a vehicle having an operator platform with a covering fixed to the operator platform which includes a driving zone for standing on by the operator when the operator is driving the vehicle and a picking zone for stepping on when the operator is picking an item from a location adjacent the operator platform.

[0009] These and still other objects and advantages of the present invention will be apparent from the description which follows. In the detailed description below, preferred embodiments of the invention will be described in reference to the accompanying drawings. These embodiments do not represent the full scope of the invention. Rather the invention may be employed in other embodiments. Reference should therefore be made to the claims herein for interpreting the breadth of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a perspective view of an orderpicker incorporating the present invention;

[0011]FIG. 2 is top view of the operator platform covering of FIG. 1;

[0012]FIG. 3 is a side view of the operator platform of FIG. 1;

[0013]FIG. 4 is a sectional view along line 4-4 of FIG. 3;

[0014]FIG. 5 is a sectional view along line 5-5 of FIG. 3; and

[0015]FIG. 6 is a sectional view of an alternative driving zone structure.

DETAILED DESCRIPTION OF THE INVENTION

[0016] As shown in FIG. 1, a lift truck 10 includes a motorized chassis 12 and an extendible mast assembly 14 mounted thereon. The mast assembly 14 lifts an operator platform 16 and a load platform 18 comprising a pair forks 20 which extend from underneath the operator platform 16. The forks 18 vertically support a pallet (not shown). The lift truck 10 can be any commercially available lift truck having an operator platform 16, such as available from The Raymond Corporation, Greene, N.Y. and BT-Prime Mover, Inc., Muscatine, Iowa.

[0017] The operator platform 16 includes a covered horizontal surface 22 on which an operator stands to operate the vehicle 10 and pick and place items for a customer order. The horizontal surface 22 has a forward edge 24 and rearward edge 26 joined by side edges 28 When driving the vehicle 10, the operator stands adjacent the forward edge 24 approximately midway between the side edges 28. When picking an item from a storage location, the operator is supported by the operator platform 16 adjacent one of the horizontal surface side edges 28. When the operator places the picked item onto the load platform 16, the operator is supported by the operator platform 16 adjacent the rearward edge 26 of the horizontal surface 22.

[0018] Referring to FIGS. 1 and 2, a floor mat 30 covers the horizontal surface 22, and includes a driving zone 32 and picking zone 34. The mat 30 is, preferably, molded from polyurethane having a Shore A durometer hardness of approximately 35, and has a forward edge 36 and rearward edge 38 joined by side edges 40 which coincide with the horizontal surface edges 24, 26, 28. Although a single piece mat 30 molded from polyurethane is preferred, the floor mat 30 can be formed from other resilient materials, such as silicone, rubber and the like, without departing from the scope of the invention. Preferably, the mat 30 is adhesively fixed to the operator platform horizontal surface 22. However, the floor mat 30 can be fixed to the horizontal surface 22 by frictional engagement, fasteners, and the like, without departing from the scope of the invention.

[0019] As shown in FIGS. 2-5, the zones 32, 34 are formed by modifying the size and shape of bumps 42, 44 molded into the mat 30 to provide a different cushioning characteristic in each zone 32, 34, as described below. Although forming the zones 32, 34 by modifying bumps 42, 44 is preferred, the zones 32, 34 can be formed from different materials having different hardnesses without departing from the scope of the invention. For example, the mat 30 can be formed from a material, such as soft plastic which is overmolded onto a base formed from a harder material, or comolded with the picking zone, to form the driving zone.

[0020] The driving zone 32 isolates the operator from at least some vibrations created by movement of the vehicle 10. Preferably, the driving zone 32 is formed in a central portion of the mat 30, and extends toward the mat forward edge 36. The driving zone 32 disclosed herein includes the closely spaced driving zone bumps 42 having a spherical diameter of approximately 25 mm and a height of approximately 4 mm with a spacing of 22 mm centers.

[0021] The driving zone bumps 42 are deformable under the weight of the operator, and act like a spring to isolate the operator from vibrations caused by the moving vehicle 10. Although driving zone bumps 42 having a specific size, shape, and spacing are disclosed, any resilient structure having a spring constant which provides cushioning to the operator can be used without departing from the scope of the present invention.

[0022] The picking zone 34 extends from the driving zone 32 toward the mat edges 36, 38, 40, and provides a stable surface to support the operator when the operator picks-or places an item. The picking zone 34 includes the closely spaced picking zone bumps 44 which has less cushioning than the driving zone bumps 42 to provide a more stable surface than the driving zone 32 for the operator.

[0023] The picking zone bumps 44 disclosed herein are closely spaced on 22 mm centers, and have a diameter of about 15 mm and height of about 2.5 mm. Advantageously, due to the resiliency of the polyurethane, forming driving zone bumps 42 having a height which is greater than the picking zone bumps 44, the driving zone bumps 42 have a spring constant which is less than the spring constant of the picking zone bumps 44 to provide more cushioning for the operator in the driving zone compared to the picking zone. Although picking zone bumps 44 having a specific size, shape, and spacing is disclosed, any resilient structure having a spring constant which is stiffer than the structure in the driving zone 32 can be used without departing from the scope of the present invention. For example, in the preferred embodiment the spacing of the bumps 42, 44 is constant and the height of the bumps 42, 44 are different to differentiate the zones 32, 34, the spacing of the bumps 42, 44 can also be different without departing from the scope of the invention.

[0024] Referring to FIG. 2, the floor mat 30 includes cutouts 46, 48, 50 which are specific to the vehicle operator platform 16. In the floor mat 30 shown in FIG. 2, corner cutouts 46 are provided to fit around vehicle structure. A circular cutout 48 is provided for a brake pedal 52 which extends therethrough for engagement by the operator. A rectangular cutout 50 is also provided in the forward edge 36 of the floor mat 30 for a pallet grip pedal 54. Of course the floor mat 30 can be provided with more or less cutouts without departing from the scope of the invention.

[0025] Referring to FIGS. 1 and 2, in use, the operator drives the lift truck 10 disclosed herein by standing on the floor mat 30 facing away from the load platform 16. The operator's left foot depresses the brake pedal 52 to disengage the brake, and is partially supported by the floor mat driving zone 32. The operator's right foot is firmly supported by the floor mat driving zone 32. As the lift truck 10 travels, the driving zone 32 isolates the operator from vibrations.

[0026] When the operator reaches a desired location, the operator engages the brake by releasing the brake pedal 52. The operator picks an item from an adjacent storage location by stepping onto the floor mat picking zone 34 proximal the side edge 40 of the floor mat 30, and reaching past the side edge 28 of the operator platform horizontal surface 22 into the storage location to grasp the desired item. The operator places the picked item onto a pallet supported by the load platform 16 by stepping onto the floor mat picking zone 34 proximal the rearward edge 38 of the floor mat 30, and reaching past the rearward edge 26 of the operator platform horizontal surface 22 toward the pallet.

[0027] In an alternative embodiment shown in FIG. 6, the spring constant of the driving zone bumps 42 can also be modified, such that it is less than the spring constant of the picking zone bumps 44 by forming a cavity 56 in the driving zone bumps 42. The cavity 56 decreases the spring constant of the driving zone bump to cushion the vehicle operator operating the lift truck 10.

[0028] While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention defined by the appended claims. 

We claim:
 1. A vehicle comprising: a chassis; an operator platform fixed to said chassis, and vertically movable relative to said chassis for lifting an operator; and a covering fixed to a horizontal surface of said operator platform, said covering having a driving zone for standing on by an operator driving the vehicle and a picking zone for stepping on by the operator when the operator picks an item from a location adjacent the vehicle.
 2. The vehicle as in claim 1, in which said driving zone cushions the operator from at least some vibrations created by movement of said vehicle.
 3. The vehicle as in claim 1, in which said driving zone has a spring constant and said picking zone has a spring constant, wherein said driving zone spring constant is less than said picking zone spring constant.
 4. The vehicle as in claim 1, in which said covering is a floor mat frictionally engaging said operator platform.
 5. The vehicle as in claim 1, in which said covering is a floor mat adhesively fixed to said operator platform.
 6. The vehicle as in claim 1, in which said driving zone is formed in a molded mat fixed to said operator platform, and said driving zone formed in said molded mat includes resilient bumps which cushion the operator from at least some vibrations created by movement of said vehicle.
 7. The vehicle as in claim 6, in which said picking zone is formed in said molded mat, and extends from said driving zone toward edges of said mat, said picking zone formed in said molded mat includes resilient bumps which supports the operator when the operator steps on the picking zone to pick an item from a location adjacent the vehicle.
 8. The vehicle as in claim 6, in which at least one of said resilient bumps define a cavity therein which provides a bump spring constant that is less than a spring constant of a like dimensioned solid bump.
 9. The vehicle as in claim 1, in which said covering is formed from a material selected from a group consisting of polyurethane, silicone, and rubber.
 10. An operator platform suitable for use on an order picker lift truck, said operator platform comprising: a horizontal surface for supporting an operator; a covering fixed to said horizontal surface, said covering having a driving zone for standing on by an operator and a picking zone for stepping on by the operator when the operator picks an item from a location adjacent the operator platform.
 11. The operator platform as in claim 10, in which said driving zone cushions the operator from at least some vibrations created by movement of said operator platform.
 12. The operator platform as in claim 10, in which said driving zone has a spring constant and said picking zone has a spring constant, wherein said driving zone spring constant is less than said picking zone spring constant.
 13. The operator platform as in claim 10, in which said covering is a floor mat frictionally engaging said horizontal surface.
 14. The operator platform as in claim 10, in which said covering is a floor mat adhesively fixed to said horizontal surface.
 15. The operator platform as in claim 10, in which said driving zone is formed in a molded mat fixed to said horizontal surface, and said driving zone formed in said molded mat includes resilient bumps which cushion the operator from at least some vibrations created by movement of said operator platform.
 16. The operator platform as in claim 15, in which said picking zone is formed in said molded mat, and extends from said driving zone toward edges of said mat, said picking zone formed in said molded mat includes resilient bumps which supports the operator when the operator steps on the picking zone to pick an item from a location adjacent the operator platform.
 17. The operator platform as in claim 15, in which at least one of said resilient bumps define a cavity therein which provides a bump spring constant that is less than a spring constant of a like dimensioned solid bump.
 18. The operator platform as in claim 10, in which said covering is formed from a material selected from a group consisting of polyurethane, silicone, and rubber.
 19. An operator platform covering suitable for use on a horizontal surface of an operator platform of an order picker truck, said covering comprising: a driving zone; and a picking zone extending from said driving zone toward edges of the covering, wherein said driving zone has a spring constant and said picking zone has a spring constant, and said driving zone spring constant is less than said picking zone spring constant.
 20. The operator platform covering as in claim 19, in which said driving zone includes resilient bumps.
 21. The operator platform covering as in claim 20, in which at least one of said resilient bumps define a cavity therein which provides a bump spring constant that is less than a spring constant of a like dimensioned solid bump.
 22. The operator platform covering as in claim 19, in which said picking zone includes resilient bumps.
 23. The operator platform as in claim 19, in which said covering is formed from a material selected from a group consisting of polyurethane, silicone, and rubber. 